AJ, Reading through this post I think the issue was not a controller but what is called an MCOR. Perhaps the OP could confirm this. An MCOR related issue can be intermittent, that's why it happened on one guy but not the other. MCOR is a $150 part and takes about 5 minutes to install, this sounds like what was replaced. I do question it being replaced, if it is indeed the issue, because if it is intermittent it is usually not an issue of replacing the part, although replacing the part will cure the problem.
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